Custom Memory Foam Mattress Manufacturing: From Firmness Design to Private Label Packaging

A 25 cm memory foam mattress can be built in many ways. One factory may use 5 cm of memory foam over a 20 cm support base. Another may use several foam layers within the same finished height. Both mattresses are 25 cm thick, but they will not have the same feel, weight, or factory price.

For a custom order, specify the mattress from the inside out. Put the thickness and foam grade of each layer on the construction drawing. Add the finished size, firmness reference, cover, and packing method. The factory can then price and sample one defined construction instead of filling in the missing details itself.

Sampling is where you check whether those numbers work together. The approved sample then becomes the reference for the cover, labels, compression, packing, and production order.

What Can You Customise in a Memory Foam Mattress?

Start with the cross-section. For example, a 25 cm mattress could contain a 4 cm memory foam top, a 5 cm transition section, and a 16 cm support base. A second model could keep the same 25 cm height but use a different layer arrangement.

You can also change the mattress width and length, foam grades, firmness, cover fabric, quilting, zipper, and packing format. Put each change under the same model code. If you order Soft and Firm versions, treat them as separate specifications rather than asking the factory to adjust the feel during production.

Mattress Length, Width, and Finished Height

Begin with exact dimensions for each SKU. Use millimetres plus centimetres rather than names such as single, queen, and king alone. Size names can represent different dimensions across sales markets.

Finished height also needs its own value. If you request a 25 cm mattress, ask the factory to show how its individual foam layers produce that finished height after the cover is fitted.

If your range contains several sizes, prepare one dimension list for the complete range. This prevents the factory from assuming that dimensions used for its existing models also apply to your products.

Number and Position of Foam Layers

Define the mattress from top to bottom. A three-layer design, for example, could place memory foam at the surface, a transition foam underneath, and then a thicker support core at the base.

Layer position should not be left open during sampling. Moving the same foam deeper into the mattress can change how much the sleeper feels it at the surface.

Give every layer a number plus its position in the construction. The sample sheet can then identify Layer 1, Layer 2, Layer 3, and so forth, making later revisions easier to record.

Comfort and Support Layer Options

Choose each foam according to the job it performs inside the mattress. The upper comfort section can use memory foam for contouring, while the lower section usually needs a firmer foam structure to support the complete mattress.

Do not specify these layers only as “memory foam” plus “base foam.” Give the manufacturer the foam type, density, and thickness for each one. For example, two 5 cm comfort layers can behave differently if their foam specifications differ.

You can also develop a transition layer between the comfort foam and support core. This gives you another way to adjust the mattress construction without changing the entire foam stack.

Firmness and Surface Feel

Treat firmness as a result of the full construction. Increasing support-core firmness alone does not tell you exactly how the sleeping surface will feel. Memory foam thickness, density, transition layers, and the cover can all influence the final response.

Give the factory a target product rather than relying only on terms such as “medium firm.” If you already sell a mattress with the desired feel, use it as a development reference. Otherwise, compare prototype versions and approve the construction that best fits your intended market.

Keep separate specifications for soft, medium, and firm models. Do not ask production workers to create different firmness levels from one loosely defined construction.

Cover Design and Appearance

The cover gives you another set of custom choices without changing the internal foam stack. You can specify fabric construction, weight, colour, pattern, quilting, border design, zipper, and logo placement.

Ask for fabric swatches before producing the complete prototype. Check the actual texture, stretch, colour, and weight rather than approving fabric from a digital image.

For a removable cover, also define the zipper position and panel construction. If the cover carries your branding, put the approved artwork and label positions into the same product specification used for sampling.

Main Custom Memory Foam Mattress Specifications

How Do You Design the Firmness of a Custom Memory Foam Mattress?

Firmness comes from the full mattress build. Memory foam depth affects how far the body settles, while the layers below control the resistance underneath. Cover construction can change the first impression as well. For this reason, give the manufacturer a target feel, then develop and test a complete construction around it.

Define the Target Feel Before Selecting Foam

Start with the feel you want to sell. Do you want noticeable contouring with a slower response, plus a flatter surface with less sink? This gives the development team a useful starting point.

A comparison sample works better than words alone. If you have an existing mattress close to your target, give the factory access to it. They can use that reference while preparing the first prototype.

Also, tell the factory where the product will sit in your range. An entry-level model and a deeper premium model may need different approaches even if both carry the same firmness description.

Adjusting Comfort-Layer Thickness

Use comfort-layer thickness to adjust how much memory foam the sleeper experiences near the surface. A deeper layer allows more sink before the body reaches the firmer foam below.

Make small changes between prototypes. Suppose the first sample uses 5 cm of memory foam and feels too deep. Test a thinner version while leaving the lower layers unchanged. You can then judge the effect of that single change.

Record the approved thickness on the construction sheet. This value should remain fixed once the sample moves into production.

Using the Support Core to Control Overall Firmness

Look at the support core if the surface feels right, but the mattress gives too much under body weight. The base foam provides resistance beneath the softer upper section.

Ask the factory to identify the core by its foam grade, density, and thickness. Do not accept “high-density base foam” as the complete specification.

During development, keep the approved upper section unchanged while testing the revised core. This helps you correct the support underneath without losing the surface feel already achieved.

Developing Different Firmness Levels for Different SKUs

Build each firmness level as its own SKU. If your range includes soft, medium, and firm versions, give each one a separate construction sheet and model code.

You do not need to redesign every layer. A factory may retain several common components and change selected layers to create the required version. The important point is to record exactly what changes between SKUs.

Use those model codes throughout sampling, production, inspection, and packing. This reduces mix-ups when several firmness versions appear in the same purchase order.

Using an Approved Sample as the Firmness Reference

Once a sample feels right, stop describing the target only as “medium” plus “firm.” Mark that mattress as the approved reference and connect it with the final construction revision.

Ask the manufacturer to retain a matching sample at the factory. If a bulk batch feels different, the QC team has something physical to compare rather than relying on a written firmness label.

The same reference also helps with repeat orders. Months later, both sides can return to an agreed product instead of trying to recreate the original feel from memory.

How Should You Specify Memory Foam for Manufacturing?

Specify each foam layer by type, density, thickness, and position. Do not send the factory descriptions such as “premium memory foam” plus “firm base foam.” Those terms give purchasing and production teams little to measure. A useful specification might state: 4 cm memory foam, 50 kg/m³, above 5 cm transition foam, and a 16 cm support core.

Memory Foam Density

Write the density in kg/m³ for every foam grade. Density tells the manufacturer how much foam mass is present within a given volume. It should appear beside the material name rather than being replaced by terms such as high density.

For example, suppose your approved comfort layer uses 50 kg/m³ memory foam. Put that value on the specification sheet and ask the factory to identify the foam grade used for the sample. During bulk production, the same value can be checked against material records and foam batch information.

Do not use density as another name for firmness. Two foams can have similar densities but respond differently because their formulations differ. Keep density and firmness requirements as separate entries.

Foam Layer Thickness

State the thickness of each layer before assembly. Writing only a total mattress height leaves the factory free to divide that height between layers.

For a 25 cm construction, your sheet might show 4 cm memory foam, 5 cm transition foam, and 16 cm support foam. If the first sample sinks too deeply, you can revise the 4 cm layer without losing track of the rest of the build.

Also state the acceptable thickness tolerance if your project requires one. This gives QC staff a defined limit when checking cut foam before assembly.

Foam Type and Formulation

Name the actual foam used in each position. Standard viscoelastic memory foam, gel-infused foam, plus other formulations should not sit under one general description if your product depends on a particular material.

Ask the manufacturer for its internal foam code as well. For example, the specification could identify Layer 1: viscoelastic memory foam, Grade MF-50, 50 kg/m³, 4 cm. That code helps purchasing and production teams order the same material for later batches.

If you approve a different formulation during sampling, update the revision number on the construction sheet. The previous foam code should no longer appear on the production order.

Support Foam Specifications

Give the base foam its own specification. Record the foam type, density, thickness, and factory material code just as you do for the memory foam layer.

For example, a construction may use 16 cm polyurethane support foam at 32 kg/m³. Treat this as a defined component rather than simply requesting a “high-density base.”

If the factory proposes another support foam to reduce cost, ask for a revised sample before approving the substitution. A base-layer change can alter the behaviour of the complete mattress even though the memory foam on top remains unchanged.

Foam Colour, Odour, and Appearance Requirements

Appearance requirements are useful when exposed foam could be seen during inspection, through a removable cover, plus during customer unpacking. State the approved colour for any foam where visual consistency is part of your product specification.

Also discuss acceptable odour with the manufacturer during sample development. Fresh foam and adhesives can have an initial smell, so check the packed prototype after opening rather than judging only an uncovered foam sheet at the factory.

Inspect foam surfaces for contamination, visible damage, poor cutting, plus unwanted colour variation before assembly. If appearance is important for your product, keep photographs of the approved foam alongside its material code.

Foam Details to Include in Your Mattress Specification

Example specification values only. The final density, thickness, and foam grade should come from the construction approved during product development.

How Is the Foam Layer Configuration Developed?

A foam layer configuration is built from the sleeping surface downward. Each layer has a separate job, but its position affects the layers around it. During development, the manufacturer should test the complete stack rather than evaluate each foam sheet separately. Once the prototype works, record the layer order so production can reproduce the same build.

Comfort Layer

The comfort layer sits directly below the mattress cover. This is usually where memory foam is placed because the sleeper interacts with this section first.

Its position should remain fixed during development. If another foam is placed above the memory foam, the surface response can change even though the same materials remain inside the mattress.

For a multi-layer comfort section, show the exact top-to-bottom order on the construction drawing. This prevents layers from being reversed during assembly.

Transition Layer

A transition layer sits between the softer upper section and the stronger base. It can reduce the sudden change between these two parts of the mattress.

Do not add this layer simply to increase mattress height. During sampling, compare the build with and without it. If the transition layer improves the intended feel, keep it as a defined part of the construction.

Its position should also be clear on production drawings. A misplaced transition layer changes the way the upper section interacts with the support core.

Support Core

The support core forms the main body of an all-foam mattress. It also provides the base on which the upper layers are assembled.

Its depth affects the space available for the comfort and transition sections. For example, increasing the upper stack in a fixed 25 cm mattress means another part of the construction must become thinner.

Keep the core as one clearly identified section on the drawing. This makes cutting, assembly, and final height checks easier on the production floor.

Zoned Foam Designs

Zoning uses different sections across the mattress rather than one uniform surface. A design may use firmer sections beneath selected body areas, channels cut into the foam, plus shaped sections that change how the mattress responds across its length.

Give the factory a drawing showing the position and dimensions of every zone. Terms such as “five-zone foam” are not enough for custom production because suppliers may use different layouts.

Check the first cut foam against the drawing before it enters the mattress assembly. Correcting a zoning error at this stage is simpler than finding it inside a finished mattress.

Total Layer Thickness vs. Finished Mattress Height

Do not assume that adding the nominal thickness of every foam sheet will always give the exact finished mattress height. The cover construction and assembly can affect the final measurement.

Keep two values on the product drawing: the individual layer stack and the required finished height. For example, the drawing can show each internal layer separately while also stating a 25 cm finished mattress height.

Measure the completed prototype after assembly. If it falls outside the agreed finished height, revise the construction before approving bulk production rather than changing individual layers on the production line.

What Should You Check Before Approving a Memory Foam Mattress Sample?

Treat the sample as the first finished unit of your order. Put it through the same conditions a customer will see: unpack it, allow it to recover, measure it, lie on it, and inspect the construction. Any correction made here should go into the final specification before the factory starts the bulk batch.

Finished Mattress Dimensions

Leave the unpacked mattress until it has recovered, then measure its length, width, and height. For height, take readings at several points rather than measuring one corner.

Suppose your drawing specifies a finished height of 25 cm. Judge the sample against the dimensional limits agreed with the factory. If one side remains noticeably lower, find the cause before approving it. The issue may come from cutting, assembly, cover tension, plus incomplete recovery after compression.

Foam Layer Thicknesses

The outside can look correct while the internal build is wrong. Verify the layer stack against the construction drawing before signing off the sample.

If the design calls for 4 cm of memory foam over a 5 cm transition layer, those are the layers you should find inside. Do not accept a changed layer simply because the factory has kept the same total mattress height.

For bulk production, the approved layer sequence becomes the reference used during foam cutting and assembly.

Surface Feel and Firmness

Do this check after the mattress has recovered from compression. Try different positions across the sleeping surface, including the centre and areas closer to the edge.

Pay attention to what happens under body weight. Does the top section allow more sink than the approved prototype? Does the base feel harder than expected? These observations are more useful than giving the mattress another general “medium-firm” rating.

If you have several firmness SKUs, place the samples together. Differences between them are much easier to judge side by side.

Cover Fit and Stitching

Walk around the mattress rather than inspecting only the top panel. Look at the corners, border seams, quilting lines, zipper, labels, and the points where different panels meet.

The cover should sit naturally on the foam build. Loose fabric around a corner plus excessive tension across the top can indicate a sizing problem.

For branded products, check logo position and label orientation at the same time. Photograph the approved sample from several sides so the sewing team has a visual reference.

Edge Shape and Overall Finish

Set the mattress on a flat base and look along each edge. Uneven sidewalls, rounded corners that should be square, visible waves, plus one side sitting higher than the other are worth investigating.

Then inspect the smaller finishing details. Loose threads, adhesive marks, foam particles under the cover, stains, plus damaged fabric should not pass simply because the mattress feels correct.

This is also a good point to view two samples beside each other. Differences in shape often become more obvious when the products are placed together.

Recovery After Unpacking

For a bed-in-a-box product, the packed sample needs its own test. Use the same compression and rolling process intended for customer orders, then open the carton as a customer would.

Watch the corners and edges during recovery. Measure the mattress again after the recovery period agreed with the manufacturer. Areas that remain compressed and a finished height that does not return within the approved range need investigation before shipment packaging is signed off.

A prototype tested only before compression does not tell you what the customer will receive after the mattress has spent time inside a carton.

Memory Foam Mattress Sample Approval Checklist

How Is the Mattress Cover Customised?

Cover development should start before the final mattress sample is sewn. Give the factory a cover sheet showing the fabric code, weight, panel layout, quilting file, colours, zipper position, and label locations. Ask for fabric swatches first. After those are approved, move to a complete sewn cover fitted to your mattress size.

Fabric Composition and Weight

Do not approve a fabric under a name such as “bamboo fabric” plus “cooling fabric.” Ask what the fabric actually contains and request its weight in g/m².

Suppose the sample uses a 300 g/m² knitted fabric. Record that weight together with the supplier's fabric code. For the production batch, the purchasing team can order against the same code rather than selecting another white fabric that looks close enough.

Ask about the backing as well. If the approved swatch has a laminated backing, that detail belongs on the cover sheet. It should not be removed later to reduce material cost.

Knitted and Woven Cover Options

Choose the fabric construction with the finished cover in mind. Knitted material has more stretch, which can help it follow the shape of an all-foam mattress. A woven panel behaves differently and may suit a design that calls for less stretch.

Ask the factory to cut A4-size swatches from the actual candidate fabrics. Small catalogue pieces make texture, pattern scale, and stretch difficult to judge.

Pull the swatch in both directions. Compare how quickly it returns and whether the pattern distorts under tension. This gives you useful information before the material is sewn onto a full mattress.

Quilting Pattern

Send the quilting artwork with dimensions. Do not send only a reference photo and ask the sewing team to make something similar.

If the pattern repeats every 15 cm, for example, put that dimension on the drawing. Also show its direction across the top panel. The factory can then prepare one quilted test panel before making the complete cover.

Look closely at the edges of that panel. Uneven stitch spacing, puckering, plus pattern distortion are easier to correct here than after dozens of top panels have been quilted.

Colour and Design

Give each panel its own colour reference. A mattress may use a white top, grey border, black piping, plus a dark bottom fabric. Put those locations on a simple cover drawing.

For custom colours, approve material from the production fabric supplier. A colour selected from a computer screen gives the mill too much room for interpretation.

If your logo is knitted into the fabric, check its actual size on the swatch. A logo that looks balanced in artwork can become oversized once repeated across a 150 × 200 cm mattress panel.

Zipper and Removable Cover Options

For a removable cover, draw the zipper route. State where it begins, where it ends, and which panel comes away after opening.

Then test the sewn cover on the mattress. Remove it and fit it again. Pay attention to the corners. If the zipper becomes difficult to close once the cover is under tension, changing the zipper specification alone may not solve the problem; the cover dimensions may need adjustment.

Also inspect the zipper tape and seam after several opening cycles. This is more useful than approving the zipper from its catalogue specification.

Fabric Swatch Approval

Keep the approved swatch as a controlled production reference. Write the supplier code, fabric weight, composition, colour code, and approval date on its sample card.

When bulk fabric reaches the factory, compare the new roll with this swatch before cutting starts. Put both pieces together and check colour, texture, stretch, pattern, and backing.

If they do not match, hold the roll for review. Once hundreds of top panels have been cut, a fabric substitution becomes much harder to correct.

What Private-Label Branding Can Be Added?

Private-label branding usually reaches several parts of the finished mattress: the side panel, sewn labels, product label, SKU identification, and carton. These items should be developed alongside the sample. Otherwise, you can end up with an approved mattress while the factory is still guessing at logo size, label position, plus model identification.

Brand Logo Placement

Logo placement depends heavily on the cover design. A large logo may work across a plain border but interfere with piping, quilting, handles, plus a zipper on another model.

Show its position directly on the cover drawing. If the logo sits at the foot end, give its width and distance from the nearest seam. The first sewn cover will tell you whether those dimensions look right on the finished mattress.

Watch knitted covers in particular. Stretching the fabric over the foam can make a printed plus knitted logo appear wider than it did on the flat panel.

Woven and Printed Labels

A small woven tag works well for visible branding along a side seam. Product names, specifications, plus longer text usually need more printable space.

Label drawings should show both the finished size and the sewing allowance. A 60 mm label does not leave 60 mm visible if part of it disappears into the seam.

Get one finished label before ordering the full batch. Fine lettering, logo shape, thread quality, and colour differences are much easier to judge on the actual piece than from a digital proof.

Care and Product Information Labels

Care labels need enough space for the final text without shrinking it until customers struggle to read it. Work from the finished label size while preparing the copy.

The wording also needs to suit the mattress being sold. Do not let an old label from another factory model become the template simply because its dimensions fit.

Placement deserves a quick check on the sample. A correct label is not very useful if the sewing team puts it behind a zipper flap, plus somewhere customers cannot easily find it.

Mattress Model Identification

Similar covers can hide very different mattresses. Model identification prevents that problem once several constructions reach the packing area.

Consider a range containing 20 cm Medium, 25 cm Medium, and 25 cm Firm models. A clear code for each version can follow the mattress from its production sheet through inspection and into the final carton.

The same code should appear wherever staff identify the product. If the mattress tag says one model while the carton carries another, the error becomes a warehouse problem rather than a manufacturing problem.

Barcode and SKU Information

Every size and model needs its matching barcode. With six mattress sizes plus several firmness versions, visually similar labels can quickly become mixed during packing.

Print a few first. Scan them and compare the returned number with the SKU sheet. Then place the mattress label beside its carton label and check the pair.

That small trial is far cheaper than discovering after shipment that a retailer's system reads the wrong SKU.

Branding Artwork Approval

The production artwork should have one final revision. Logo dimensions, label layouts, barcodes, colours, and placement drawings all need to point to that version.

This becomes important after sample changes. If Logo V2 was approved but Logo V1 remains inside the production package, either file could reach the printing supplier.

Before the full run, place the finished woven label, printed label, logo panel, and carton proof beside the approved sample. Once those pieces match, the branding side of the mattress

How Does Packaging Affect Container Loading?

Container utilisation comes down to the dimensions and gross weight of the packed units. Once these figures are available for each SKU, you can build the shipment around the actual order mix. This is more useful than using a factory's general estimate of mattresses per container.

Carton Dimensions by Mattress Size

Create a packing data sheet for every mattress size. Record the outer carton dimensions after packing, since these are the dimensions used for the loading layout.

For example:

• 90 × 200 cm mattress: 32 × 32 × 105 cm packed

• 150 × 200 cm mattress: 38 × 38 × 105 cm packed

• 180 × 200 cm mattress: 42 × 42 × 105 cm packed

These are example figures, not standard carton sizes. Your supplier should provide measurements from your packed samples.

A useful check is carton volume. A 38 × 38 × 105 cm carton occupies about 0.152 m³ before loading allowances are considered. This gives purchasing teams a quick way to compare the shipping volume of different SKUs.

Gross Weight Per Carton

Put the gross shipping weight beside each carton dimension. For example, a mattress may weigh 27.5 kg before packing and 29 kg after the bag, carton, labels, and other packing components are included.

Use the 29 kg figure in shipment calculations.

Weight also needs checking against the loading quantity. If 700 cartons each weigh 29 kg, the cargo alone reaches 20,300 kg. At that point, both available container space and applicable weight limits need to be considered.

Units Per Container

Do not calculate container quantity from cubic metres alone. Rolled mattress cartons have fixed shapes, and unused gaps can remain between rows, near doors, plus above the final stack.

Request a loading layout for the selected container type. It should show carton orientation, cartons per row, number of rows, and total units.

For a new SKU, treat the first loading as useful production data. Record the planned quantity beside the quantity that physically entered the container. Future orders can then use the actual result rather than another estimate.

Mixed-Size Loading Plans

A mixed container needs its own calculation because carton dimensions change across the order.

Consider a purchase containing:

• 300 cartons of SKU A

• 200 cartons of SKU B

• 100 cartons of SKU C

Calculate the space taken by those quantities first. You can then see whether the remaining container space can take additional units of a particular SKU.

This is especially useful during purchase-order planning. If only a small volume remains, adding a smaller packed size may use the available space better than adding another large-carton model.

Warehouse Space After Arrival

Container utilisation should not be the final calculation. The same carton data can be used to plan receiving space.

For example, 500 cartons at 0.15 m³ each represent 75 m³ of packed product before allowing for aisles, pallets, racking, and handling space.

Also check the maximum intended stacking height. If a warehouse can only stack a particular carton four units high, the floor-space requirement will differ from a warehouse designed for higher stacks.

This calculation becomes particularly useful when several containers arrive within a short receiving period.

What MOQ Applies to Custom Memory Foam Mattresses?

MOQ is often set by the least flexible part of the order. Mattress assembly may accept 300 units, while custom fabric requires material for 600 covers. Printed cartons may have another minimum. The quotation should separate these quantities so you can see what is driving the first-order commitment.

MOQ Per Mattress Model

Factories normally plan production around a defined construction. Changing the firmness, layer arrangement, or finished height can turn one product range into several production models.

This becomes relevant with small launch quantities. If 400 mattresses are split between four different constructions, the factory is not necessarily running one 400-piece job. It may be setting up four 100-piece jobs.

For a new range, fewer constructions can make the opening order easier to place. More variations can be introduced once sales justify larger individual runs.

MOQ Per Size

Different widths do not always require separate model minimums. A factory may cut several sizes from the same approved construction during one production run.

The restriction often appears in the quantity allocated to each size. A planned order of 500 pieces might contain only 40 units of a slow-moving king size. That small line is the figure worth discussing.

Have the quotation show the lowest accepted quantity beside each size. You can then change the size ratio without redesigning the mattress itself.

Custom Foam and Fabric Requirements

Custom materials can create a larger commitment than the finished-mattress MOQ. Consider a cover fabric made specifically for your brand. The mill produces 1,000 metres, while the first mattress run consumes 650 metres. The commercial question is what happens to the remaining 350 metres.

That balance can stay at the factory for the next order, be charged immediately, or sometimes carry a storage period. Put the arrangement into the purchase terms. Otherwise, unused material can become a disagreement several months later.

A special foam formulation can create the same situation if the foam supplier works with minimum production batches.

MOQ for Branded Labels and Cartons

Branding components are usually inexpensive per piece, but their production runs can exceed the mattress quantity.

For example, 400 mattresses may require payment for 1,000 woven labels. Using the remaining 600 on the next order is usually more practical than increasing the mattress quantity just to consume them.

Cartons are different because each physical size may need its own cutting die plus print run. If three mattress sizes use three carton dimensions, look at the printer's minimum against each carton rather than the combined number of boxes.

Mixed-SKU Orders

A mixed order works best when the factory allows quantities to be balanced across sizes using the same construction.

Imagine an MOQ of 300 units for one mattress model. A workable split might be 100 single, 120 double, and 80 king mattresses if the supplier accepts the 300 as one run. If the minimum applies to every size, the same range requires 900 units.

That single distinction can change the investment in a new product line substantially. Put the proposed SKU quantities into the RFQ from the beginning. The supplier can then quote against the range you intend to purchase rather than against an abstract MOQ.

What Should Be Confirmed Before Bulk Production Starts?

Before bulk production, the sample, specification, artwork, PO, and packing details should describe the same mattress. This is the point to close the development work. Production should not have to choose between old and new files or work out which sample change was finally accepted.

Final Construction Sheet

Use the construction sheet that matches the last sample.

Imagine three samples were made. Sample 2 changed the transition layer, while Sample 3 kept that change and reduced the finished height. The sheet released to production needs both changes.

Give that sheet a revision code. The same code can appear on the sample approval record, which makes the correct version easy to identify later.

Approved Foam Specifications

By this stage, each foam should have a fixed specification and factory material code.

The practical check is simple: take the final construction sheet and compare its foam codes with the materials reserved for the order. If the sheet says MF-50 and purchasing has ordered MF-45, production should not begin while that difference is unresolved.

This check is particularly useful where several visually similar foam grades are kept in the factory.

Approved Physical Sample

The final sample stays useful after development finishes. Keep one approved unit at the factory and identify it with the model, date, and revision.

Production staff can refer back to it when something is difficult to judge from a drawing. QC can use the same unit when the first mattresses come off the line.

Older prototypes should be clearly marked as rejected, superseded, or development samples. Otherwise, they can easily return as references several weeks later.

Cover and Branding Files

This stage is mainly file control. The cover drawing, quilting file, logo artwork, labels, and barcode data should all carry the versions approved during sampling. Remove earlier artwork from the production set.

One useful practice is to issue a single artwork index. It can show, for example, Cover C03, Logo L02, Care Label CL04, Side Label SL02. The factory then knows exactly which files belong to that order.

Packaging Specification

Use the packing trial as the reference for the production packing sheet. Record the carton used for each SKU together with its packing method and artwork version.

Pay attention to similar carton sizes. A 150 cm and 160 cm mattress may arrive at the packing line looking almost identical once rolled. The packing sheet needs enough identification to keep the two carton versions apart.

Any carton change made after the trial should be reflected in the shipping calculations before production release.

Order Quantity and Size Breakdown

The factory needs the PO in production quantities, not only a grand total. A 1,000-piece order could contain eight SKUs. Put the quantity beside each SKU and reconcile the lines back to 1,000. If 30 extra units are required for replacement stock plus another agreed purpose, show them separately instead of allowing production to add them informally.

This quantity sheet becomes the common number for planning, packing, and final shipment count.

Production and Shipment Dates

Work backwards from the cargo-ready date. If loading is booked for 28 November, production cannot simply be scheduled to finish on 27 November. The batch may still need final inspection, packing completion, documentation, plus corrective work from inspection findings.

Put those dates on the order schedule. A buyer can then see the actual margin between production completion and loading instead of discovering late that both dates were treated as the same deadline.

The production release can be a dated sign-off against this list. If something changes afterwards, issue the changed document under a new revision. That leaves a clear record of what the mattress factory was authorised to manufacture.